Professional Documents
Culture Documents
2010 Caterpillar
All Rights Reserved
SEBU7028-02
November 2001
Operation and
Maintenance
Manual
D250E Series II and D300E Series II
Articulated Trucks
4PS1-Up (Machine)
5KS1-Up (Machine)
119
Maintenance Section
Maintenance Interval Schedule
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When Required
Battery - Recycle ................................................ 123
Battery, Battery Cable or Battery Disconnect Switch Replace ............................................................. 124
Cab Air Filter - Clean/Replace ............................ 128
Circuit Breakers - Reset ...................................... 129
Engine Air Filter Primary Element Clean/Replace .................................................. 139
Engine Air Filter Secondary Element - Replace .. 141
Engine Air Filter Service Indicator - Inspect ........ 141
Engine Air Precleaner - Clean ............................ 143
Ether Starting Aid Cylinder - Replace ................. 146
Frame and Body - Inspect ................................... 147
Fuses and Circuit Breaker - Replace/Reset ....... 153
In-Line Refrigerant Dryer - Check and Replace .. 159
Oil Filter - Inspect ................................................ 160
Radiator Core - Clean ......................................... 163
Seat - Inspect ...................................................... 163
Seat Belt - Replace ............................................. 164
Walk-Around Inspection ...................................... 174
Window Washer Reservoir - Fill .......................... 176
Window Wiper - Inspect/Replace ........................ 176
Windows - Clean ................................................. 177
120
Maintenance Section
Maintenance Interval Schedule
130
133
134
134
135
136
Every 3 Years
Seat Belt - Replace ............................................. 164
121
Maintenance Section
Air Conditioner - Test
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Illustration 142
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122
Maintenance Section
Axle Breathers - Clean/Replace
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Illustration 145
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Illustration 144
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Illustration 146
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123
Maintenance Section
Battery - Recycle
Illustration 147
Battery - Recycle
SMCS Code: 1401-561
1. Always recycle a battery. Never discard a battery.
2. Always return used batteries to one of the
following locations.
Illustration 148
g00602831
A battery supplier
Recycling facility
Interval
Conventional
100 Hours
Low Maintenance
250 Hours
Maintenance Free
No Interval
124
Maintenance Section
Battery, Battery Cable or Battery Disconnect Switch - Replace
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Illustration 149
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125
Maintenance Section
Brake Pads - Check
Illustration 150
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Illustration 152
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Illustration 151
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126
Maintenance Section
Brakes, Indicators and Gauges - Test
operation.
127
Maintenance Section
Braking System - Test
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engine setting
engine power
engine efficiency
brake holding ability
When the machine begins to move, the engine rpm
should be compared to a previous test. Use the
comparison as an indication of system deterioration.
1. Before you test the service brake, apply the
parking brake. Move the transmission control to
the NEUTRAL position. Start the engine. Allow
the engine to fully charge the brake system.
2. Apply the service brake. Move the transmission
control to the FIRST SPEED FORWARD position.
Release the parking brake.
3. Gradually increase the engine rpm. The service
brake should prevent the machine from moving
away when the engine is running at 1700 rpm.
128
Maintenance Section
Cab Air Filter - Clean/Replace
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Illustration 155
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Illustration 154
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129
Maintenance Section
Circuit Breakers - Reset
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Illustration 157
Illustration 156
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Alternator (4)
130
Maintenance Section
Cooling System Coolant (DEAC) - Change
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Illustration 158
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NOTICE
Do not change the coolant until you read and understand the material found in the Operation and Maintenance Manual, Cooling System Specifications section. Failure to do so could result in damage to the
cooling systems components.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
If the Diesel Engine Antifreeze/Coolant (DEAC) is
dirty or if you observe any foaming in the cooling
system, drain the coolant before the recommended
interval.
Illustration 159
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131
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Do not change the coolant until you read and understand the material found in the Operation and Maintenance Manual, Cooling System Specifications section. Failure to do so could result in damage to the
cooling systems components.
NOTICE
Mixing Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar products or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems
components.
132
Maintenance Section
Cooling System Coolant Additive (DEAC) - Add
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Illustration 161
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NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration. Excessive
supplemental coolant additive concentration can
form deposits on the higher temperature surfaces of
the cooling system, reducing the engines heat heat
transfer characteristics. Reduced heat transfer could
cause cracking of the cylinder head and other high
temperature components. Excessive supplemental
coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated
water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if
equipped) at the same time. The use of those additives together could result in supplemental coolant
additive concentration exceeding the recommended
six percent maximum.
133
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
1. Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the
dump body and stop the engine.
2. Raise the hood.
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Recommended Amount
of Caterpillar Extender
22 to 30 L (6 to 8 US gal)
30 to 38 L (8 to 10 US gal)
38 to 49 L (10 to 13 US gal)
49 to 64 L (13 to 17 US gal)
64 to 83 L (17 to 22 US gal)
Illustration 162
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134
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
Illustration 163
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Illustration 164
135
Maintenance Section
Cooling System Water Temperature Regulator - Replace
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136
Maintenance Section
Crankshaft Vibration Damper - Inspect
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NOTICE
Former water temperature regulators may be used, if
they meet test specifications and are not damaged or
have excessive buildup or deposits.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a water temperature regulator.
Depending on load, failure to operate with a water temperature regulator could result in either an overheating
or an overcooling condition.
NOTICE
If the water temperature regulator is installed incorrectly, it will cause the engine to overheat.
6. Install a new seal in the water temperature
regulator housing. Install a new water
temperature regulator and a new gasket. Install
the water temperature regulator. Install the water
temperature housing.
7. Install the elbow and the hose. Tighten the hose
clamp.
8. Add the cooling system coolant. Maintain the
coolant level within 13 mm (.50 inch) of the
bottom of the filler tube.
Illustration 166
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137
Maintenance Section
Differential and Final Drive Oil - Change
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Illustration 168
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Illustration 167
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138
Maintenance Section
Differential and Final Drive Oil Level - Check
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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139
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
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Illustration 172
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Illustration 171
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140
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
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Illustration 175
Illustration 174
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141
Maintenance Section
Engine Air Filter Secondary Element - Replace
Illustration 177
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Illustration 178
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142
Maintenance Section
Engine Air Filter Service Indicator - Inspect
Illustration 180
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Type 2. Indicator
Illustration 179
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Type 1. Indicator
143
Maintenance Section
Engine Air Precleaner - Clean
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Illustration 183
Illustration 181
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Illustration 182
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144
Maintenance Section
Engine Oil Sample - Obtain
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NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Illustration 185
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Illustration 184
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145
Maintenance Section
Engine Valve Lash - Check
Illustration 186
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Illustration 188
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Illustration 187
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146
Maintenance Section
Engine Valve Rotators - Inspect
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NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar Dealer for the complete engine valve lash
adjustment procedure.
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Illustration 189
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147
Maintenance Section
Frame and Body - Inspect
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Front frame
Rear frame
A-frames
Oscillating hitch
Dump body
The age of the machine
The severity of the application
The loads that have been carried on the machine
The condition of the haul road
NOTICE
The areas highlighted are of particular importance but
other areas must not be neglected. The entire structure must be carefully examined.
148
Maintenance Section
Frame and Body - Inspect
Front Frame
Illustration 191
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Illustration 193
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Oscillating Hitch
Illustration 194
Illustration 192
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Rear Frame
arms
Illustration 195
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149
Maintenance Section
Fuel Injection Timing - Check
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A-Frames
Illustration 196
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dump Body
Illustration 197
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150
Maintenance Section
Fuel System - Prime
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel
spills immediately.
NOTICE
The fuel injection nozzles can be permanently damaged by twisting if only one wrench is used to loosen
or tighten the fuel line nuts.
Use one wrench to hold the nozzle and another to
loosen the nut.
1. Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the
dump body and stop the engine.
2. Wrap dry cloths around the fuel injection nozzles
in order to soak up the fuel.
Illustration 199
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151
Maintenance Section
Fuel System Primary Filter - Clean/Inspect/Replace
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152
Maintenance Section
Fuel Tank Cap and Strainer - Clean
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Note: Before you replace the secondary fuel filter,
the primary fuel filter must be replaced. Refer to the
Operation and Maintenance Manual, Fuel System
Primary Filter - Clean/Inspect/Replace.
1. Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the
dump body and stop the engine.
Illustration 202
Illustration 201
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153
Maintenance Section
Fuel Tank Water and Sediment - Drain
Illustration 203
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Illustration 204
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7. Install the fuel tank strainer and the fuel tank cap.
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Fuses
Illustration 205
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154
Maintenance Section
Hoist Cylinder Bearings - Lubricate
If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer
Engine Starting Aid 10 amp
Seat 15 amp
Electronic System Test Switch 10 amp
Horn 10 amp
Circuit Breakers
The circuit breakers are located on the fuse panels.
Push in on the button in order to reset the circuit
breaker.
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155
Maintenance Section
Hydraulic System Oil - Change
Illustration 206
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Illustration 207
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Illustration 208
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156
Maintenance Section
Hydraulic System Oil Filter, Strainer and Breather - Replace/Clean
Illustration 209
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Strainer
Illustration 210
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157
Maintenance Section
Hydraulic System Oil Level - Check
Illustration 211
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Breather
Illustration 212
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Illustration 213
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158
Maintenance Section
Hydraulic System Oil Sample - Obtain
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Illustration 215
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159
Maintenance Section
In-Line Refrigerant Dryer - Check and Replace
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Illustration 216
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Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
Check
1. Raise the cab in order to gain access to the
in-line refrigerant dryer.
Refer to the Operation and Maintenance Manual,
Cab Tilt.
160
Maintenance Section
Oil Filter - Inspect
Illustration 217
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Replacement
Illustration 218
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Illustration 219
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161
Maintenance Section
Oscillating Hitch - Adjust
Illustration 222
Illustration 220
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162
Maintenance Section
Oscillating Hitch - Lubricate
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Illustration 224
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Illustration 225
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163
Maintenance Section
Radiator Core - Clean
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Illustration 226
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NOTICE
Do not attempt to straighten the ROPS structure. Do
not repair the ROPS by welding reinforcement plates
to the structure.
If there are any cracks in the welds, in the castings, or
in any metal section of the ROPS, consult your Caterpillar dealer for repairs.
Illustration 227
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Seat - Inspect
SMCS Code: 7312-040
Check the operation of the seat adjustment levers.
Ensure that the seat can be adjusted properly for
maximum support for the operator.
164
Maintenance Section
Seat Belt - Replace
Inspect the fabric for the seat cushion for wear and
inspect the fabric for the backrest for wear.
Illustration 228
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Illustration 229
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165
Maintenance Section
Suspension System - Check/Adjust
When the suspension is lowered clearances between the machine frames and suspension components are reduced.
Illustration 230
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Illustration 231
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166
Maintenance Section
Suspension and Suspension Cylinder Bearings - Lubricate
Illustration 232
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Illustration 233
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167
Maintenance Section
Tailgate and Tailgate Cylinder Bearings - Lubricate
Illustration 234
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Illustration 236
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Illustration 237
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168
Maintenance Section
Torque Converter Scavenge Screen - Clean
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Illustration 240
Illustration 241
Illustration 238
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Illustration 239
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169
Maintenance Section
Torque Converter, Transmission, and Transfer Gear Oil - Change
Torque Converter,
Transmission, and Transfer
Gear Oil - Change
SMCS Code: 3030-044-OC; 3101-044-OC;
3159-044-OC
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 242
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5. The oil level dipstick and the oil filler cap for the
transmission oil are located on the left side of
the machine under access cover (2). Open the
access cover in order to expose oil level dipstick
(3) and transmission oil filler cap (4).
170
Maintenance Section
Torque Converter, Transmission, and Transfer Gear Oil Filter - Replace
6. Clean the area around filler cap (4) and filler tube
(5). Remove the filler cap. Fill the transmission
with new oil through the filler tube. Fill the
transmission to the COLD SAFE START mark
on the oil level dipstick. Refer to the Operation
and Maintenance Manual, Refill Capacities
and the Operation and Maintenance Manual,
Lubricant Viscosities.
7. Clean the oil filler cap. Install the oil filler cap.
8. Start the engine. Run the engine at low idle.
Inspect the transmission for leaks.
9. Ensure that the parking brake is fully engaged.
Apply the service brakes. Slowly operate the
transmission control in order to circulate the oil.
10. Maintain the transmission oil level at the FULL
HOT LOW IDLE mark on the oil level dipstick.
Add oil through the filler tube, if necessary.
Illustration 244
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Torque Converter,
Transmission, and Transfer
Gear Oil Filter - Replace
SMCS Code: 3067-510; 3101-510-FI; 3159-510-FI
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
171
Maintenance Section
Torque Converter, Transmission, and Transfer Gear Oil Level - Check
Torque Converter,
Transmission, and Transfer
Gear Oil Level - Check
SMCS Code: 3030-535-FLV; 3101-535-FLV;
3159-535-FLV
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 246
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The oil filler cap has been removed from the filler tube.
The oil level dipstick has been partially removed.
Illustration 247
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The oil level dipstick and the oil filler for the
transmission oil are located on the left side of the
machine under the access cover.
172
Maintenance Section
Torque Converter, Transmission, and Transfer Gear Oil Sample - Obtain
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Torque Converter,
Transmission, and Transfer
Gear Oil Sample - Obtain
Illustration 248
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Illustration 249
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173
Maintenance Section
Transmission and Transfer Gear Breather - Clean/Replace
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Illustration 250
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Illustration 251
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V-Belts - Inspect/Adjust/
Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the dump
body and stop the engine.
174
Maintenance Section
Walk-Around Inspection
Illustration 252
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Illustration 254
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Walk-Around Inspection
SMCS Code: 7000-040
For maximum service life of the machine, perform a
thorough walk-around inspection before you mount
the machine and before you start the engine.
Illustration 253
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175
Maintenance Section
Wheel Bearings - Check/Adjust
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176
Maintenance Section
Wheel Nut Torque - Check
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Typical Example
Illustration 257
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177
Maintenance Section
Windows - Clean
Windows - Clean
SMCS Code: 7310-070
Illustration 258
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